Insulating container and method of forming such a container

ABSTRACT

An insulating container can be configured to retain a mass of food and/or beverages, and include an outer shell with a cuboidal shape and a first opening extending into a first inner cavity. The insulating container may also have an inner structure with an inner cuboidal shape and a second opening extending into the second inner cavity. A flange may be coupled between the outer shell and the inner structure to seal the first opening such that the outer shell is offset from the inner structure. A sealed vacuum cavity may be formed within the insulated double wall structure between the outer shell and the inner structure. Further, a bracing structure may brace a planar surface of the outer shell against the vacuum within the vacuum cavity.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of, and priority to, U.S. Provisional Patent Application No. 62/291,679, filed Feb. 5, 2016. The content of which is expressly incorporated herein by reference in its entirety for any and all non-limiting purposes.

FIELD

The present disclosure herein relates broadly to containers, and more specifically to rigid insulated containers used for beverages or foods.

BACKGROUND

A container may be configured to store food and/or a volume of liquid. Containers may be composed of rigid materials, such as a metal. These containers can be formed of a double-wall vacuum-formed construction to provide insulative properties to help maintain the temperature of the food or beverage within the container.

BRIEF SUMMARY

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. The Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

In certain examples, an insulating container can be configured to retain a mass of food and/or beverages. The insulating container can include an outer shell that has an outer cuboidal shape with a first opening at the top side of the container that extends into a first inner cavity. The container may also have an inner structure with an inner cuboidal shape that has a second opening at the top side of the container that extends into a second inner cavity. Further, the container may have a flange, or a flange surface, positioned between the outer shell and the inner structure at the top side of the container that seals the first opening, with the outer shell offset from the inner structure. An insulated double wall structure between the outer shell and the inner structure may form a sealed vacuum cavity therebetween, and a bracing structure may brace a planar surface of the outer shell.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is illustrated by way of example and not limited in the accompanying figures in which like reference numerals indicate similar elements and in which:

FIG. 1 depicts an isometric view of an insulating container, according to one or more aspects described herein.

FIG. 2 depicts an isometric view of the insulating container of FIG. 1 coupled to a lid structure in a closed configuration, according to one or more aspects described herein.

FIG. 3 schematically depicts an isometric view of the insulating container of FIG. 1 decoupled from the lid structure, according to one or more aspects described herein.

FIG. 4 depicts an isometric view of another example of an insulating container, according to one or more aspects described herein.

FIG. 5 depicts another isometric view of the insulating container of FIG. 1, according to one or more aspects described herein.

FIG. 6 schematically depicts the insulating container of FIG. 1 showing hidden lines, according to one or more aspects described herein.

FIG. 7 schematically depicts an exploded isometric view of the insulating container of FIG. 1, according to one or more aspects described herein.

FIG. 8 schematically depicts an exploded isometric view of the insulating container having an additional bottom portion, according to one or more aspects described herein.

FIG. 9 schematically depicts an exploded isometric view of the insulating container turned upside down, according to one or more aspects described herein.

FIG. 10 schematically depicts an isometric view of the insulating container configured with two tab offset elements, according to one or more aspects described herein.

FIG. 11 depicts a more detailed view of the offset elements from FIG. 10, according to one or more aspects described herein.

FIG. 12 schematically depicts a section view of an alternative implementation of an offset structure, according to one or more aspects described herein.

FIG. 13 depicts an isometric view of an outer shell structure, according to one or more aspects described herein.

FIG. 14 schematically depicts another isometric view of the insulating container, according to one or more aspects described herein.

FIG. 15 schematically depicts another isometric view of the insulating container, according to one or more aspects described herein.

FIGS. 16A and 16B schematically depict a coupling and hinge mechanism that may be utilized with the insulating container of FIG. 1, according to one or more aspects described herein.

FIG. 17 schematically depicts a cross-sectional view of another implementation of an insulating container, according to one or more aspects described herein.

Further, it is to be understood that the drawings may represent the scale of different components of various examples; however, the disclosed examples are not limited to that particular scale.

DETAILED DESCRIPTION

In the following description of the various examples, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration various examples in which aspects of the disclosure may be practiced. It is to be understood that other examples may be utilized and structural and functional modifications may be made without departing from the scope and spirit of the present disclosure.

Aspects of this disclosure relate to an insulating container. FIG. 1 depicts an isometric view of an insulating container 100. In one example, the insulating container 100 may have a substantially cuboidal shape. Further, the insulating container 100 may be coupled to a lid structure 102. As such, FIG. 1 depicts the insulating container 100 coupled to the lid structure 102 in an open configuration. In one implementation, the lid structure 102 may be hingedly-coupled to the insulating container 100. For example, the lid structure 102 may be hingedly-coupled to the insulating container 100 along a first edge 104 of a top portion 106 of the insulating container 100. Accordingly any hinge mechanism may be utilized to hingedly-couple the lid structure 102 to the insulating container 100, including, among others, a piano-type hinge along a full length of first edge 104, or one or more hinges positioned at intervals along the first edge 104. In one example, a hinged coupling between the lid structure 102 and the insulating container 100 may utilize a flexure (e.g. a polymer flexure) along at least a portion of the first edge 104. Other examples of hinge mechanisms that may be utilized with the insulating container 100 and the lid structure 102 may be envisaged without departing from the scope of these disclosures.

In one implementation, the lid structure 102 may comprise a double wall construction. As such, one or more cavities formed within the lid structure 102 may be partially or wholly filled with an insulating material. It will be appreciated such an insulating material may comprise one or more polymeric materials (e.g. a foam, a lattice, a substantially solid structure, and the like). Additionally or alternatively, the lid structure 102 may comprise a vacuum-insulated double wall structure. In yet another example, the lid structure 102 may comprise one or more vacuum-insulated panel structures, and such that one or more vacuum-insulated panels (not depicted) may be positioned within the lid structure 102 in order to increase thermal resistance. In one example, the lid structure may include one or more vacuum-insulated panels (otherwise referred to as discs), such as those described in U.S. application Ser. No. 14/971,788, entitled “Closure and Lid and Method of Forming Closure and Lid,” filed 16 Dec. 2015, the entire contents of which are incorporated herein by reference in their entirety for any and all non-limiting purposes.

FIG. 2 depicts an isometric view of the insulating container 100 coupled to a lid structure 102 in a closed configuration. In one example, the lid structure 102 may be held in the closed configuration depicted in FIG. 2 using one or more fasteners that may be configured for removable coupling, or resealable sealing, of the lid structure 102 to the insulating container 100 along a second edge 112. As such, FIG. 2 schematically depicts fasteners 108 and 110 configured to removably couple the lid structure 102 to the insulating container 100 along the second edge 112. The fasteners 108 and 110 may comprise cam locking mechanisms, clips, ties, hooks, straps, T-latches, an interference fitting, or any other mechanism configured for removable coupling of the lid structure 102 to the insulating container 100. These fastener types can be configured to be quick release fasteners in order to allow the user to easily open and close the lid structure on the insulating container 100. Moreover, in one example, the container could simply include a flange gasket without any additional securing methods. In one example, a single fastener, or three or more fasteners may be used along the second edge 112 to removably couple the lid structure 102 to the insulating container 100. In addition to, or as an alternative to the one or more fasteners (e.g. fasteners 108 and 110) along with a second edge 112, one or more fasteners may be utilized on a third edge 114 and/or a fourth edge 116 to removably couple the lid structure 102 to the insulating container 100 to hold the lid structure 102 in the depicted close configuration of FIG. 2 relative to the insulating container 100. In yet another example, a zip fastener may be utilized along at least a portion of one or more of the first edge 104, the second edge 112, the third edge 114, and/or the fourth edge 116.

FIG. 3 schematically depicts an isometric view of the insulating container 100 decoupled from a lid structure 302. The lid structure 302 may be configured to be fully decoupled from the insulating container 100, rather than hingedly-coupled, as described for the lid structure 102. Accordingly, the lid structure 302 and/or the insulating container 100 may comprise one or more fasteners allowing for removable coupling of the lid structure 302 to the insulating container 100. While not depicted FIG. 3, it will be appreciated that one or more fasteners may be utilized along one or more of the first edge 104, the second edge 112, the third edge 114 and/or the fourth edge 116.

FIG. 4 depicts an isometric view of another example of an insulating container 400. The insulating container 400 may be similar to insulating container 100, and may be coupled to a lid structure 402. Accordingly, the lid structure may be similar to lid structure 102 and/or lid structure 302. FIG. 4 depicts a more detailed view of one example of a fastening mechanism comprising fasteners 404 and 406. However, it will be readily appreciated that a single fastener, or three or more fasteners may be utilized, without departing from the scope of these disclosures. Describing fastener 404 in further detail, a tab structure 408 may be hingedly-coupled to the lid structure 402 at a first end 410, and configured to be manually-engaged with a receiving structure 412 that is coupled to the insulating container 400.

FIG. 5 depicts an isometric view of the insulating container 100. The substantially cuboidal outer shape of the insulating container 100 may comprise substantially planar surfaces. Surfaces 120 and 122 represent two of five substantially planar surfaces, which may comprise four side surfaces and one bottom surface, of the insulating container 100. The insulating container 100 may further comprise a top surface, otherwise referred to as a flange surface 124. The flange surface 124 may be configured with a gasket (compression gasket, flange gasket or otherwise) configured to form a seal when the insulating container 100 is coupled to the lid structure (e.g. lid structure 102 or 302 as previous described) in a closed configuration. An opening in the top surface 124 extends into a cavity 126 configured to store an item (one or more food or beverage items, e.g. a solid, liquid or combination thereof, among others) to be insulated by the container 100. The inner structure of the insulating container 100 may also have a substantially cuboidal shape similar to the outer shape of the insulating container 100, and comprising five substantially planar surfaces, of which surfaces 128 and 130 are two examples.

In one implementation, the insulating container 100 may comprise an insulated double wall structure, as schematically depicted in FIG. 6. In particular, FIG. 6 schematically depicts the insulating container 100 showing hidden lines. As such, FIG. 6 schematically depicts an insulated double wall structure formed by an outer shell 134, and an inner structure 136 of the insulating container 100. Accordingly, the insulated double wall structure may be configured to form a vacuum cavity 132 between the outer shell 134 and the inner structure 136.

FIG. 7 schematically depicts an isometric exploded view of the insulating container 100. In one implementation, and as schematically depicted in FIG. 7, the insulating container 100 may be constructed from two primary elements, including the outer shell 134, and the inner structure 136. As such, the outer shell 134 may be constructed using one or more sheet-metal deep-drawing and/or stamping processes, and using, in one example, a stainless steel sheet-metal. Separately, the inner structure 136 may be constructed using one or more sheet-metal deep-drawing and/or stamping processes. Similar to the outer shell 134, the inner structure 136 may be constructed using a stainless steel sheet-metal. However, it will be readily appreciated that the insulating container 100 may be constructed using one or more additional or alternative metals and/or alloys, one or more fiber-reinforced materials, one or more polymers, or one or more ceramics, or combinations thereof, among others, without departing from the scope of these disclosures. In one example, the one or more deep-drawing and/or stamping processes utilized to produce the geometry of the inner structure 136 may also form the flange surface 124.

In one example, the inner structure 136 of the insulating container 100 may be rigidly coupled to the outer shell 134 by one or more coupling processes that are configured to couple the flange surface 124 to one or more of the edges 104, 112, 114, and/or 116. In one specific example, the inner structure 136 may be secured to the outer shell 134 by a welding operation utilizing a robotic arm and camera system in conjunction with a stationary electrode or the like to ensure that inner structure 136 is connected to the outer shell 134 along the flange surface 124. These coupling processes may also include one or more brazing or welding processes (including, among others, shielded metal arc, gas tungsten arc, gas metal arc, flux-cored arc, submerged arc, electroslag, ultrasonic, cold pressure, electromagnetic pulse, laser beam, or friction welding processes). In another example, the outer shell 134 may be rigidly coupled to the inner structure 136 by one or more adhesives, by a sheet metal hem joint, or by one or more fastener elements (e.g. one or more screws, rivets, pins, bolts, or staples, among others).

FIG. 8 schematically depicts an exploded isometric view of the insulating container 100 having an additional bottom portion 802. Accordingly, the insulating container 100, as previously described, may include the outer shell 134 that is configured to be rigidly coupled to the inner structure 136. In one example, the bottom portion 802 may be referred to as an end cap 802, and may be configured to be seamlessly coupled to a bottom portion 804 of the outer shell 134. In one implementation, the end cap 802 may be configured to cover one or more elements configured to facilitate the formation of a low vacuum volume within the vacuum cavity 132 between the outer shell 134 and the inner structure 136. As such, one or more coupling processes, similar to those described in relation to the coupling of the outer shell 134 to the inner structure 136, may be utilized to rigidly couple the end cap 802 to the outer shell 134.

FIG. 9 schematically depicts an exploded isometric view of the insulating container 100 in an inverted position. In one example, the insulating container 100 may be positioned in the depicted configuration of FIG. 9 in order to form a low vacuum volume within the vacuum cavity 132. Implementations of insulating structures that utilize one or more vacuum chambers to reduce heat transfer by conduction, convection and/or radiation may be utilized within the insulating container 100. To achieve a vacuum between the walls of the container (e.g. between the outer shell 134 and the inner structure 136), at least a portion of air within the container 100 may be removed by positioning the container 100 within a larger chamber (not depicted), and removing at least a portion of the air from the vacuum cavity 132 by pulling a vacuum within the larger chamber (not depicted) (e.g. reducing an internal pressure of the larger chamber to a pressure below an internal pressure within the vacuum cavity 132). Further, it will be appreciated that any techniques and/or processes may be utilized to reduce a pressure within the larger chamber (not depicted), including, vacuum pumping, among others. As such, a portion of air within the vacuum cavity 132 may escape through an opening extending between a dimple structure 902 on the base surface 906 of the insulating container 100, and the vacuum cavity 132. It will be appreciated that the dimple structure 902 may be positioned anywhere on the base surface 906, and that more than one dimple structure 902 may be utilized with the insulating container 100. Additionally or alternatively, one or more dimple structures, similar to dimple structure 902, may be positioned on one or more alternative surfaces of the insulating container 100, without departing from the scope of these disclosures. In order to seal a vacuum within the vacuum cavity 132, the insulating container 100 can be oriented in an inverted configuration as schematically depicted in FIG. 9 within a vacuum formation chamber, and a resin 904, which can be in the shape of a pill, can be placed into the divot or dimple 902 during the vacuum forming process. In certain examples, the resin can be approximately 3 mm to 5 mm in diameter, and the openings in the dimples 902 can be approximately 1 mm in size. Accordingly, the vacuum formation chamber may be heated to a temperature at which the resin 904 becomes viscous. In one example, the viscosity of the resin 904 may be such that the resin 904 does not flow or drip into the container through the opening, but is permeable to air such that the air can escapes the internal volumes of the vacuum cavity 132. In one implementation, a vacuum forming process may heat the insulating container 100 to temperature of approximately 550° C. In other implementations, during the vacuum forming process the insulating container may be heated to approximately 200° C., 250° C., 300° C., 350° C., 400° C., 450° C., 500° C., or 600° C., among others. Following a period of heating, the insulating container 100 may be passively or actively cooled to room temperature. As such, once the resin 904 cools and solidifies, it covers the openings of the dimple 902, and seals the internal volume of the container 100 (e.g. the vacuum cavity 132) to form a vacuum between the insulated double wall structure formed between the outer shell 134 and the inner structure 136. A plate structure or disc (not depicted in FIG. 9) may be rigidly coupled to the base surface 906 in order to cover the dimple structure 902 once a vacuum has been formed, as previously described. Accordingly, any fastening process may be utilized to rigidly couple said plate structure or disc to the base surface 906 (including, among others, one or more welding, soldering, and/or brazing processes). Additionally, it will be understood that the described vacuum may be formed within the vacuum cavity 132 of the insulating container 100 without the depicted end cap 802, without departing from the scope of these disclosures. Further details of the vacuum formation process, and of the use of a seamless end cap, similar to end cap 802, are described in U.S. Provisional Application No. 62/237,419, entitled “Container and Method of Forming a Container,” filed 5 Oct. 2015, the entire contents of which are incorporated herein by reference in their entirety for any and all non-limiting purposes.

In certain implementations, a pressure within the vacuum cavity 132 of the insulating container 100 may measure less than 15 μTorr. In other examples, the vacuum may measure less than 10 μTorr, less than 50 μTorr, less than 100 μTorr, less than 200 μTorr, less than 400 μTorr, less than 500 μTorr, less than 1000 μTorr, less than 10 mTorr, less than 100 mTorr, or less than 1 Torr, among many others. Accordingly, a vacuum within the vacuum cavity 132 of the insulating container 100 may cause deformation of one or more surfaces of the insulating container 100. For example, turning again to FIG. 5, one or more of surfaces 120 and 122 may partially deform due to a pressure differential between a pressure external to the insulating container 100 (i.e. atmospheric pressure), and an internal vacuum pressure within the vacuum cavity 132.

In one implementation, in order to prevent or reduce a deformation of one or more surfaces of the insulating container 100, one or more of the structures of the insulating container 100 may be configured with wall thicknesses configured to provide structural rigidity to resist deformation. Accordingly one or both of the outer shell 134 and the inner structure 136 may have wall thicknesses (i.e. may utilize a sheet-metal thickness) ranging at or between 0.2 mm to 40 mm or approximately 0.5 mm, 1 mm, 1.5 mm, 2 mm, 2.5mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, or 30 mm, among others.

In another implementation, in order to prevent or reduce a deformation of one or more surfaces of the insulating container 100, one or more tab offset elements 1002, 1004 may be utilized. These tab offset elements 1002, 1004 may also be referred to as bracing elements or bracing structures. Accordingly, FIG. 10 schematically depicts an isometric view of the insulating container 100 configured with two tab offset elements 1002 and 1004. As such, the tab offset elements 1002 and 1004 may be rigidly coupled to the inner structure 136. In particular, the tab offset elements 1002 and 1004 may be rigidly coupled to a first surface 1006 of the inner structure 136. It will be appreciated that any means of rigidly coupling the offset structures 1002 and 1004 to the first surface 1006 may be utilized, without departing from these disclosures. For example, the offset structures 1002 and 1004 may be welded, riveted, bolted, glued (e.g. using an epoxy), or screwed to the first surface 1006. Additionally, while two offset structures 1002 and 1004 are depicted in FIG. 10, and may be utilized to prevent or reduce a deformation of surface 120 of the outer shell 134, a single offset structure may be utilized. Alternatively, three or more of such structures may be utilized. Further, offset structures (not pictured) may be utilized on one or more additional or alternative outer surfaces of the inner structure 136, such as surface 1008. The number of offset structures can be provided based on the size of the container and the pressure that the container needs to withstand during vacuumization. Additionally or alternatively, the offset structures, such as offset structures 1002 and 1004, may be rigidly coupled to an inner surface of the outer shell 134, such as to surface 128 or surface 130.

FIG. 11 depicts a more detailed view of the offset elements 1002 and 1004 from FIG. 10. In one implementation, an offset element may comprise a base structure 1102 that is rigidly coupled to a surface, such as surface 1006. As depicted in FIG. 11, the base structure 1102 may comprise a C-shaped structure, however alternative geometries may be utilized to create an offset distance, without departing from the scope of these disclosures. In one example, an offset element, such as offset element 1002, may comprise a contact structure 1104, which may be configured to abut, and prevent or reduce a deformation of another surface, such as an inner surface of the outer shell 134. In one implementation, the contact structure 1104 may comprise a material with a softer structure than the base structure 1102 and/or the surface with which the contact structure 1104 is to make contact. As such, the contact structure 1104 may be formed from one or more polymeric materials and other materials that have insulative properties. The contact surface may also be formed of materials that have elastomeric properties. For example, any suitable elastomeric materials, such as rubber, polyurethanes, polybutadiene, neoprene, or silicone, may be used. These may be applied by any known fastening methods such as mechanical fastening or adhesives and the contact structure 1104 may, in certain instances, be in the form of an adhesive. Accordingly, contact structure 1104 may be configured to partially deform upon contact with another surface to allow for a certain degree of deflection between the inner shell and the outer shell. In one example, the contact structure 1104 may partially deform upon contact with another surface and decrease a pressure exerted on, in one example, the outer shell 134. As such, this decreased pressure may reduce or avoid indentation of the outer shell 134, among others. It will be appreciated that any polymer may be utilized to construct the contact structure 1104, without departing from the scope of these disclosures. In an alternative implementation, an offset element, such as offset element 1002, may be constructed from a single material, such that a structure 1104 is formed from a same material as the base structure 1102.

FIG. 12 schematically depicts a section view of an alternative implementation of an offset structure 1200. In particular, FIG. 12 schematically depicts a boss offset structure 1200, which may be used in addition to, or as an alternative to, one or more of the offset elements 1002 and 1004. The boss offset structure 1200 may comprise a boss that is integrally formed as part of a surface of the insulating container 100. As such, boss offset structure 1200 may be integrally formed with a surface 1202, which may be similar to surface 1006. In one example, bumper structures 1204 and 1206 may be coupled to the boss offset structure 1200, and configured to abut surface 1208, which may be an internal surface of the outer shell 134. Accordingly, the bumper structures 1204 and 1206 may be coupled to the boss offset structure 1200 using any coupling structure (including, among others, one or more rivets, screws, bolts, welds, or adhesives). The bumper structures 1204 and 1206 can be formed of a non-conductive material, such as a polymer and can in certain instances have elastomeric properties and can be formed of the materials mentioned herein.

FIG. 13 depicts an isometric view of an outer shell structure 134. Accordingly, FIG. 13 depicts another structure that may be utilized to prevent or reduce a deformation of one or more surfaces of the insulating container 100 as a result of a pressure differential between the previously described vacuum cavity 132, and an external environment (atmospheric pressure). In one example, a ribbing structure 1302 may be utilized to prevent or reduce a deformation of a surface of the outer shell 134. As depicted in FIG. 13, the ribbing structure 1302 may be formed as a corrugated-like structure with a plurality of corrugations. The ribbing structure 1302 may be formed as a single plate structure configured to be rigidly-coupled to an inner surface of the outer shell 134. As such, any coupling process or structure may be utilized to rigidly couple the ribbing structure 1302 to the outer shell 134. In an alternative implementation, the ribbing structure 1302 may be integrally formed with the outer shell 134 during one or more deep drawings processes using a die configured to produce the corrugated-like structure as depicted in FIG. 13. In an alternative implementation, one or more structural ribs may be separately coupled to the outer shell 134. Further, an orientation of the ribbing structure 1302 may be different to that depicted in FIG. 13, without departing from the scope of these disclosures. The ribbing structure 1302 may also in certain examples, provide a certain outward appearance or aesthetic look of the container by providing style lines and in certain examples may provide the exterior of the container with certain grooves, gripping elements or handles for the user to grasp or hold the container during use. Additionally, it will be readily apparent that the ribbing structure 1302 described in FIG. 13 may be utilized with the inner structure 136, without departing from the scope of these disclosures.

FIG. 14 schematically depicts another isometric view of the insulating container 100. Accordingly, in one implementation, the insulating container 100 may be configured to include one or more vacuum-insulated panels, such as vacuum-insulated panel 1402. As such, the vacuum insulated panel 1402 may be positioned within the cavity 132, as schematically depicted in FIG. 6. It will be appreciated that the vacuum-insulated panel 1402 may be configured to approximately completely cover the surface 1006, without departing from the scope of these disclosures. In another implementation, the vacuum-insulated panel 1402 may be configured to cover a portion of the surface 1006, among others. Additionally or alternatively, one or more vacuum-insulated panels may be arranged in an array on the surface 1006, to provide for reduced heat transfer between the internal cavity 126 and the external environment.

In one implementation, the vacuum-insulated panel 1402 may comprise an internal vacuum cavity. Further, the vacuum-insulated panel 1402 may have a structural rigidity such that it may be utilized to contact, and prevent or reduce a deformation of one or more surfaces of the insulating container 100, such as surface 120. In one example, when the insulating container 100 is configured with one or more vacuum-insulated panels, such as panel 1402, within the insulated double wall structure between the outer shell 134 and the inner structure 136, the cavity 132 may not be evacuated to form a vacuum. However, in another implementation, in addition to utilizing one or more vacuum-insulated panels, such as panel 1402, a vacuum may be formed within the cavity 132. Further details regarding the vacuum-insulated panel 1402 are described in U.S. Provisional Application No. 62/259879, entitled “Insulating Container Having Vacuum Insulated Panels and Method,” filed 25 Nov. 2015, the entire contents of which are incorporated herein by reference in their entirety for any and all non-limiting purposes.

FIG. 15 schematically depicts another isometric view of the insulating container 100. Accordingly, in one implementation, the insulating container 100 may be configured to include an insulating structure 1502 within the insulated double wall structure formed between the outer shell 134 and the inner structure 136. Accordingly, the insulating structure 1502 may include one or more of a foam, a lattice structure, a honeycomb structure, or a substantially solid insulating structure. As such, the insulating structure 1502 may be formed from aluminum or stainless steel or one or more of a metal, an alloy, a polymer, a ceramic, an organic material, or a fiber-reinforced material among others, which may have a degree of porosity to provide the desired insulating properties. Similar to the vacuum-insulated panel 1402 described in relation to FIG. 14, the insulating structure 1502 may comprise one or more discrete structures arranged in an array, or a single structure configured to wholly or partially fill the cavity 132 that is formed between the outer shell 134 and the inner structure 136. Further, the insulating structure 1502 may be positioned on one or more outer surfaces of the inner structure 136, such as surface 1006. Additionally, the insulating container 100 may or may not utilize a vacuum within the cavity 132 in addition to the insulating structure 1502. In addition to providing increased resistance to thermal conductivity, the insulating structure 1502 may have a structural rigidity configured to prevent or reduce a deformation of one or more surfaces of the insulating container, such as surface 120.

In relation to the a ribbing structure 1302, vacuum-insulated panel 1402, and the insulating structure 1502, it is also contemplated that these structures can be formed of smaller sections or pieces similar to the tab offset elements 1002, 1004 to provide the requisite structure to prevent deformation of the insulating container during the vacuumization process. FIGS. 16A and 16B schematically depict a coupling and hinge mechanism that may be utilized with the insulating containers described herein. In particular, FIG. 16A schematically depicts a portion of the insulating container 100 and a portion of the lid structure 102. As previously described in relation to FIG. 3, the lid structure 102 may be configured to be removable from the insulating container 100. In one implementation, a magnetic mechanism may facilitate a removable and hinged coupling between the lid structure 102 and the insulating container 100. In one example, the insulating container 100 may have one or more tab structures, e.g. tab structures 1602 a and 1602 b, configured to be received into corresponding recesses 1604 a and 1604 b. It will be appreciated that the depicted portion of the lid structure 102 and the insulating container 100 may comprise additional tab structures and corresponding recesses positioned periodically along a length of the insulating container 100, such as along edge 104. Additionally, the lid structure 102 and the insulating container 100 may comprise magnetic hinge elements 1606 a-1606 d and 1608 a-1608 d. In one implementation, these magnetic hinge elements 1606 a-1606 d and 1608 a-1608 d may comprise cylindrical permanent magnets. In other implementations, different magnet geometries may be utilized, without departing from the scope of these disclosures. Further, any permanent magnet material and strength type may be utilized, without departing from the scope of these disclosures.

As depicted in FIG. 16A, the magnetic hinge elements 1606 a-1606 d and 1608 a-1608 d may allow the lid structure 102 to be removed from the insulating container 100. However, when brought into proximity with one another, as schematically depicted in FIG. 16B, the insulating container 100 and the lid structure 102 may align along axis 1610 as a result of magnetic attraction between the magnetic hinge elements 1606 a-1606 d and 1608 a-1608 d. Further, this magnetic attraction may facilitate hinged motion of the lid structure 102 relative to the insulating container 100 about axis 1610, without decoupling of the lid structure 102 from the insulating container 100. As such, in order to decouple the lid structure 102 from the insulating container 100, a threshold force may be applied in a direction perpendicular to axis 1610. This can help to provide a quick release lid structure 102 for packing and/or cleaning purposes.

In another example, the lid structure can be provided with a hinge on one edge. The hinge can be a permanent hinge or can be a removable hinge and may be formed of any suitable metal, alloy, or plastic components. In one example, the hinge could be quickly released by the use of an easily removable hinge pin or a hinge pin may be embedded into the edge of the lid structure while allowing for the lid to easily break away from the insulated container once the user applies a threshold force to the lid from removing the lid from the container.

FIG. 17 schematically depicts a cross-sectional view of another implementation of an insulating container 1700. Similar to insulating container 100, insulating container 1700 may comprise an outer shell 1702 rigidly-coupled to an inner structure 1704, and forming an internal cavity 1703. Accordingly, the outer shell 1702 and the inner structure 1704 may be constructed using one or more materials and/or manufacturing techniques similar to those described in relation to the outer shell 134 and the inner structure 136. Further, a vacuum cavity 1706 may be formed between the outer shell 1702 and the inner structure 1704. This vacuum cavity may be formed using one or more similar techniques to the vacuum cavity 132. In one implementation, the outer shell 1702 may be directly-coupled to the inner structure 1704 along a seam 1708 at a top side of the insulating container 1700. In one implementation, the seam 1708 may be a weld beam/seam, such that the outer shell 1702 is coupled to the inner structure 1704 by one or more welding processes. However, additional or alternative coupling techniques and mechanisms may be utilized with the insulating container 1700, without departing from the scope of these disclosures. For example, the outer shell 1702 may be coupled to the inner structure 1704 by one or more adhesives, fasteners, or by crimping/folding portions of the outer shell 1702 and inner structure 1704 to form a coupling therebetween. Accordingly, the insulating container 1700 may be constructed without a flange surface, such as the flange surface 124. In one example, the insulating container 1700 may comprise a press-fitting between surface portion 1710 of the outer shell 1702, and surface portion 1712 of the inner structure 1704. It will be appreciated that the cross-sectional geometry of the insulating container 1700 may vary from that schematically depicted in FIG. 17, without departing from the scope of these disclosures. As such, the insulating container 1700 may be constructed with any external and internal volumes, or any length, width or height dimensions.

In one example, an insulating container formed of a material can include an outer shell that has an outer cuboidal shape with a first opening at the top side of the container that extends into a first inner cavity. The container may also have an inner structure with an inner cuboidal shape that has a second opening at the top side of the container that extends into a second inner cavity. Further, the container may have a flange, or a flange surface, positioned between the outer shell and the inner structure at the top side of the container that seals the first opening with the outer shell offset from the inner structure. A sealed vacuum cavity may form an insulated double wall structure between the outer shell and the inner structure, and a bracing structure may brace a planar surface of the outer shell.

The insulating container may be formed of stainless steel, and the bracing structure may have a bracket that is rigidly coupled to an outer surface of the inner structure, and configured to contact an inner surface of the outer shell. The bracing structure may have a ribbing structure, and the ribbing structure may be integrally formed with the outer shell. Alternatively, the ribbing structure may be formed separately to the outer shell, and rigidly coupled to an inner surface of the outer shell.

In one example, the insulating container may have a bracing structure that has a lattice structure positioned within the sealed vacuum cavity. In another example, the bracing structure may comprise a vacuum-insulated panel positioned within the sealed vacuum cavity. In yet another example, the bracing structure may comprise a boss structure, and the boss structure may be integrally-formed with the inner structure of the insulating container.

In one implementation, the insulating container may have a lid, and may be removably-coupled to the lid by a magnetic hinge element.

A method of forming an insulating container can include one or more of forming an outer shell with an outer cuboidal shape with a first opening at the top end of the container extending into a first inner cavity. The method can also include forming an inner structure defining an inner cuboidal shape with a second opening as the top end of the container extending into a second inner cavity. A flange may be integrally formed with the inner structure and extend around the second opening. A bracing structure may be formed, and configured to brace a planar surface of the outer shell. The method may further include rigidly coupling the flange to the outer shell to seal the first opening, and evacuating a mass of gas from a cavity between the outer shell and the inner structure to form a vacuum-insulated double wall structure.

The present disclosure is disclosed above and in the accompanying drawings with reference to a variety of examples. The purpose served by the disclosure, however, is to provide examples of the various features and concepts related to the disclosure, not to limit the scope of the disclosure. One skilled in the relevant art will recognize that numerous variations and modifications may be made to the examples described above without departing from the scope of the present disclosure. 

What is claimed is:
 1. An insulating container comprising: an outer shell defining an outer cuboidal shape with a first opening at a top side of the container extending into a first inner cavity; an inner structure defining an inner cuboidal shape with a second opening at the top side of the container extending into a second inner cavity; a flange, coupled between the outer shell and the inner structure at the top side of the container to seal the first opening, and such that the outer shell is offset from the inner structure; a insulated double wall structure forming a sealed vacuum cavity between the outer shell and the inner structure; and a bracing structure configured to brace a planar surface of the outer shell.
 2. The insulating container of claim 1, wherein the container is formed of stainless steel.
 3. The insulating container of claim 1, wherein the bracing structure comprises a bracket rigidly coupled to an outer surface of the inner structure, and configured to abut an inner surface of the outer shell.
 4. The insulating container of claim 1, wherein the bracing structure comprises a ribbing structure.
 5. The insulating container of claim 4, wherein the ribbing structure is integrally formed with the outer shell.
 6. The insulating container of claim 4, wherein the ribbing structure is rigidly coupled to an inner surface of the outer shell.
 7. The insulating container of claim 1, wherein the bracing structure comprises a lattice structure positioned within the sealed vacuum cavity.
 8. The insulating container of claim 1, wherein the bracing structure comprises a vacuum-insulated panel within the sealed vacuum cavity.
 9. The insulating container of claim 1, wherein the bracing structure comprises a boss structure.
 10. The insulating container of claim 9, wherein the boss structure is integrally-formed with the inner structure.
 11. The insulating container of claim 1, further comprising a lid configured to resealably-seal the second opening.
 12. The insulating container of claim 11, wherein the lid is removably-coupled to the insulating container by a magnetic hinge element.
 13. A method of forming an insulating container comprising: forming an outer shell defining an outer cuboidal shape with a first opening at a top end of the container extending into a first inner cavity; forming an inner structure defining an inner cuboidal shape with a second opening at the top end of the container extending into a second inner cavity, the inner structure having a flange, integrally formed with the inner structure, and extending around the second opening; forming a bracing structure configured to brace a planar surface of the outer shell; rigidly coupling the flange to the outer shell to seal the first opening; and evacuating a mass of gas from a cavity between the outer shell and the inner structure to form a vacuum-insulated double wall structure.
 14. The method of claim 13, wherein the outer shell and the inner structure are formed using stamping processes.
 15. The method of claim 13, wherein the bracing structure comprises a ribbing structure.
 16. The method of claim 15, wherein the ribbing structure is integrally formed with the outer shell.
 17. The method of claim 15, wherein the ribbing structure is rigidly coupled to an inner surface of the outer shell.
 18. The insulating container of claim 13, wherein the bracing structure comprises a boss structure.
 19. The insulating container of claim18, wherein the boss structure is integrally-formed with the inner structure.
 20. An insulating container comprising: an outer shell defining an outer cuboidal shape with a first opening at a top side of the container extending into a first inner cavity; an inner structure defining an inner cuboidal shape with a second opening at the top side of the container extending into a second inner cavity, the inner structure rigidly coupled to the outer shell at the top side of the container; a insulated double wall structure forming a sealed vacuum cavity between the outer shell and the inner structure; and 